Bobbin assemblies

ABSTRACT

A bobbin assembly comprising a bobbin having an axial core passage and flanges at each end of the bobbin with a coil of wire wound round the bobbin between the flanges and a housing formed on one or more of the flanges and provided with recesses within which the ends of the coil and the ends of power supply leads can be engaged together with a sleeve crimping the ends together. A fuse may be mounted in a further passage formed in the bobbin and extending parallel to the core passage and the housing may be provided with recesses to receive sleeves, crimping the ends of the fuse to an end of the wire of the coil and to a power supply lead. In both cases a cover is engaged with the housing and the arrangement is such that the cover cannot be removed from the housing when a core is engaged in the core passage.

United States Patent Norman Lane l-lalesowen, England Aug. 12, 1969 June 15, 1971 BSR Limited Cradley Heath, Warley, England [32] Priority Aug. 16, 1968, Oct. 16, 1968 [33] Great Britain [31 39246/68 and 49091/68 [72] inventor [21] vAppl. No. [22] Filed [45] Patented [73] Assignee [54] BOBBIN ASSEMBLIES 10 Claims, 2 Drawing Figs.

[52] 11.8. CI 317/13, 317/15, 317/157.6, 336/105, 336/192, 336/198 [51] Int. Cl H02h 7/00, H01f27/30 [50] Field of Search 1. 336/105,

[56] References Cited UNITED STATES PATENTS 2,787,743 4/1957 Hultgren 336/198 X Primary Examiner-Thomas J. Kozma Attorney Kurt Kelman ABSTRACT: A bobbin assembly comprising a bobbin having an axial core passage and flanges at each end of the bobbin with a coil of wire wound round the bobbin between the flanges and a housing formed on one or more of the flanges and provided with recesses within which the ends of the coil and the ends of power supply leads can be engaged together with a sleeve crimping the ends together. A fuse may be mounted in a further passage formed in the bobbin and extending parallel to the core passage and the housing may be provided with recesses to receive sleeves, crimping the ends of the fuse to an end of the wire of the coil and to a power supply lead. in both cases a cover is engaged with the housing and the arrangement is such that the cover cannot be removed from the housing when a core is engaged in the core passage.

PATENTED JUN 1 5-1971 SHEET 2 UP 2 BOBBIN ASSEMBLIES BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to bobbin assemblies of the type, hereinafter referred to as of the type specified," which comprise a bobbin having a core passage within which a core element can be received and the bobbin provides a former around which a plurality of turns of wire are made to provide a coil of the bobbin assembly.

2. Description of Prior Art The coil has to be connected to power supply leads. The wire of the coil is relatively thin and that of each power supply lead is relatively thick and hitherto the connection between the two wires has been achieved by soldering the ends of the wires together. Each power supply lead is then secured to the bobbin by threading the end of the lead through holes in the bobbin to secure the lead to the bobbin. An insulating sleeve is then put over the soldered joint between the power supply lead and the wire of the coil. The coil is then encircled by an adhesive tape to protect the wire and the connection between the power supply lead and the wire of the coil is positioned between two adjacent turns of the tape.

Thus, it has hitherto been necessary to pass the power supply leads through holes in the bobbin and to place the insulating sleeve over the connection by hand. It has also been necessary to perform the taping operation by hand because of the need to manipulate the connection between the power supply lead and the wire of the coil into position between the two adjacent turns of the tape.

SUMMARY OF THE INVENTION An object of the invention is to provide an improved bobbin assembly whereby the taping operation may be automatically performed and wherein the connection of the wire of the coil to the power supply lead is facilitated.

The'invention is a bobbin for a bobbin assembly of the type specified wherein the bobbin is provided with a housing to receive, in use, an end of a power supply lead and an end of the wire of the coil and a sleeve crimping said ends together, said housing being adapted to receive a removable cover and being positioned relative to said core passage in the bobbin so that when a core is positioned in said core passage said cover is retained in position on said housing.

From another aspect the invention is a bobbin assembly including a bobbin as set out in the preceding paragraph and having a coil of wire wound thereon and having an end of a power supply lead and an end of the wire of the coil crimped together by a sleeve and engaged in said housing.

Viewed from another aspect the invention is a method of making a bobbin assembly of the type specified comprising the steps of taking a bobbin as set out in the penultimate paragraph, winding a plurality of turns of wire around the bobbin, crimping an end of the wire of the coil to a power supply lead by means of a sleeve positioned over said ends and positioning said sleeve and ends in said housing.

BRIEF DESCRIPTION OF DRAWINGS Two bobbin assemblies according to the invention will now be described in more detail by way of example with reference to the accompanying drawings wherein:

FIG. 1 is an exploded perspective view of a bobbin assembly according to the invention, and,

FIG. 2 is an exploded perspective view of another bobbin assembly according to the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIG. 1, a bobbin assembly comprises a bobbin, indicated generally at 10, and a coil, indicated generally at 11. The coil .11 comprises a plurality of turns of relatively thin wire 12 coated with a lacquer insulator. The bobbin 10 comprises a tubular part 13 .having a central core passage 14 and is of generally rectangular configuration and provides a former around which the turns of the coil 11 are wound.

The core passage 14 is provided to receive the core of the stator of an electric motor with which the bobbin is to be used. It will be appreciated, however, that, if desired, the bobbin may be used in other applications than in electric motors, for example in a transformer.

At each end of the tubular part 13 the bobbin is provided with flanges 15 which extend normal to the longitudinal axis of the passage 14 and are of generally square configuration and provide end faces 16 of the bobbin.

A housing l7is provided on one end face 16 of the bobbin adjacent a side 18 of the passage 14. 1

The housing 17 comprises two generally U-shaped recesses 19a and 19b which are provided by upstanding walls 20 formed on the flange 15.

One limb of each recess 19a, 19b is closed at its outer end 21.

A groove 22 is fonned in each of two opposite sides 23 of the housing 17, which sides 23 extend generally normal to the side 18 of the passage 14. I

The limbs 24 of each recess 18a, 19b which are closed at their one ends 21 are of such dimensions as to snugly receive sleeves 25 which are crimped to power supply leads 26 and the ends 27 of the wire 12 of the coil 11 to secure the ends of the coil 11 to their associated power supply leads.

As will be apparent from the drawings the standing parts of the wires 26 and 27 extend along the base and the other limb of each generally U-shaped recess 19a, 1912. Two narrow slots 28 are formed in the flange 15 in the base of the open ended limb of each recess 19 to enable the ends 27 of the wire 12 to be passed from the coil into the recesses 19a, 19b.

A cover 30 is provided for the housing 20 and the cover 30 is closed at one end 31 and at its two sides 32. lnwardly directed flanges 33 are provided on the cover 30 and engage within the grooves 22 provided on the housing 17.

In use, the wire 12 is wound automatically on the tubular part 13 of the bobbin 10. A self-adhesive tape is then automatically wrapped around the external surface of the coil 12.

The free ends 27 of the coil 11 are then crimped to the free ends of the power supply leads 26 by the sleeves 25 in conventional manner and then the ends 27 and the power supply leads 26 are engaged within the recesses 19a, 19b, as explained hereinbefore. The cover 30 is then slid onto the housing 17 by sliding the cover 30 in a direction normal to the edge 18 of the core passage 14 and in the direction away from the passage 14 until the end wall 31 of the cover 30 engages the inwardly directed edge 34 of the housing 17.

When the bobbin assembly is in use a core member is engaged within the core passage 14 and this prevents subsequent removal of the cover 30 as it prevents a sliding of the cover 30 towards the passage 14. Removal of the cover 30 by continued sliding movement in the direction away from the side 18 is prevented as a result of abutment of the sidewall of the cover which closes the one end 31 with the bottom side 34 of the housing 17. Referring now to FIG. 2, the second embodiment of the invention is of basically similar construction to the first embodiment and again comprises a bobbin, indicated generally at and a coil, indicated generally at 111. The coil 111 comprises a plurality of turns of relatively thin wire 112 coated with a lacquer insulator. The bobbin 110 comprises a tubular part 113 having a central core passage 114 and is of generally rectangular configuration and provides a former around which the turns of the coil 111 are wound.

The core passage 114 is provided to receive the core of the stator of an electric motor with which the bobbin assembly is to be used. It will be appreciated, however, that if desired, the bobbin assembly may be used in other applications than in electric motors, for example it may be used in a transformer.

At each end of the tubular part 113 the bobbin is provided with flanges 115 which extend normal to the longitudinal axis of the passage 115 and are of generally square configuration and provide end faces 116 of the bobbin.

A further passage 117 is formed in the tubular part 113 and is of rectangular configuration and extends parallel to the core passage 114.

A housing-118 is provided on one end face 116 of the bobbin. The housing comprises a pair of generally U-shaped recesses 119, 120 with a straight recess 121 situated therebetween The recesses 119, 120 end 121 are constituted by upstanding walls 122 formed on the flange 115. The two U-shaped recesses 119, 120 have one of their limbs closed at its outer end 123.

A groove 124 is formed in each of the opposite sides of the housing 118, which grooves extend generally normally to a side 125 of the passage 114. The open ended limbs of the recesses 119, 120 and the recess 121 are both provided with slits 128 in the flange 115 which communicate with the "coil" side of the flange 115. The closed limbs of the U-shaped recesses 119 and 120 are of such dimensions as to snugly receive sleeves 129, 129a which are crimped t the power supply leads 131 and 131a. A further sleeve 130 is crimped to the end 132 of the core 112 and is received in the recess 121. The sleeves 129 and 130 are also crimped to the free ends 133 of thermal fuse 134.

The thermal fuse 134 comprises two wires 135 soldered together, at 136, by a metal having a melting point such that it -melts at a predetermined temperature so that when the temperature of the junction between the wires 135 reaches the predetermined temperature the metal melts and breaks the electric circuit to the coil of the bobbin. Adjacent the ends 133 and wires 135 are moulded within a member 137 made of synthetic plastics material and of generally T-configuration.

ln use, the 37 standing" parts of the power supply leads 131 and 131a are received in the open ended limbs of the recesses 119 and 120 whilst the sleeves 129 and 129a are received in the close ended limbs thereof.

The sleeve 129 is crimped to the power supply lead 131 and one wire 133 of the thermal fuse 134. A slit 128a is formed in the bottom of the recess 119 to permit the wire 133 to enter the recess.

The sleeve 129a of the mains lead 131a is crimped to the other end 138 of the coil 112, the end 138 having been passed through a slit 128 of the recess 120.

The sleeve 130 which crimps together the other end 133 of the thermal fuse 134 and the end 132 of the coil 112 is engaged in recess 121 and there is a slit 128a formed in the bottom of the recess 121 to permit the other end 133 of the thermal fuse to enter the recess.

The ends 133 of the fuse 134 project from the recesses 119 and 121 and the T-shaped member 137 is positioned so that the shank of the T is engaged in the further passage 117 and so that the connection 136 between the wires 135 of the thermal fuse is positioned just inwardly of the other end of the passage 117.

A cover 140 is provided for the housing 118 and the cover 140 is closed at one end 141 and at its two sides 142. lnwardly directed flanges 143 are provided on the cover 140 and engage within the grooves 142 provided on the housing 118.

The cover 140 is adapted to cover the head of the T-shaped member 137 and hence prevent removal of the T-shaped member from the further passage 117 when the cover is in position on the housing.

The bobbin assembly is assembled by winding the wire 112 around the tubular part 113 of the bobbin 110 automatically. A self-adhesive tape 139 is then automatically wrapped around the external surface of the coil 111. The free ends 132 and 138 of the coil 111 are then stripped oftheir lacquer insulator and are then fastened respectively to one end 133 of the thermal fuse 134 and the power supply lead 131a by the sleeves 130 and 129a respectively. Similarly the other power supply lead 131 is crimped by sleeve 129 to the other free end 133 of the thermal fuse 134 and the sleeves 129, 130 and 129a are then engaged within the recesses 119, and 121 and the thermal fuse is engaged within the passage 117.

The cover 140 is then slid onto the housing 118 by sliding the cover 140 in a direction normal to the edge of the passage 114 and in the direction away from the passage 114 until the end wall 141 of the cover engages the inwardly directed sides 144 of the housing 120.

A core member is then engaged within the core passage 114 and this prevents subsequent removal of the cover 140 as it prevents sliding of the cover 140 in the direction towards the passage 114. The cover 140 cannot be removed by continued sliding in the direction away from the passage 114 because of the abutment between the end wall 141 and the inwardly directed sides 144 of the housing 120.

lf desired, the core passage 14 of the first embodiment or 114 of the second embodiment may be of any desired shape and can be circular or hexagonal, for example. In all cases, the parallel sides of the housing with the grooves extend in a direction parallel with a line extending normal to the central longitudinal axis of the core passage.

Although one housing on one side of the passage on a flange at one end of the passage has been described herein, if desired, one or more housings may be provided at one or both ends of the passage, and more than one housing may be provided at spaced angular positions about the longitudinal axis of the passage.

It will be appreciated that the present invention provides a very convenient bobbin assembly whereby the connection of the power supply leads to the coil of the bobbin assembly is facilitated. The bobbin assembly of the present invention also enables automatic'taping of the coil of the bobbin assembly because there is removed the need to thread the power supply leads to holes in the bobbin, and because there is no need to provide an insulating sleeve over the connection of the power leads of the coil.

1 claim:

1. A bobbin assembly comprising a bobbin having an axial core passage provided therein,'an outwardly extending flange provided on each end of the bobbin and a coil of wire wound around the bobbin between the flanges, wherein the improvement comprises a housing provided on one of said flanges, and end ofa power supply lead and an end of the wire of the coil being crimped together by a sleeve and engaged in said housing, a cover engaged with said housing and means to prevent removal of the cover from the housing when a core is engaged in said core passage.

2. A bobbin assembly according to claim 1 wherein the housing includes a recess, said wire ends and said sleeve crimping said ends together being engaged in said recess.

3. A bobbin assembly according to claim 1 wherein the housing includes two recesses, one of said recesses having said wire ends and said sleeve crimping said ends together engaged therein and the other recess having an end of another power supply lead and the other end of the wire of the coil together with a sleeve crimping said ends together engaged therein.

4. A bobbin assembly according to claim 2 wherein a fuse is mounted on the bobbin and is connected in series with said coil.

5. A bobbin assembly according to claim 4 wherein a further passage is formed in the bobbin and extends parallel to said core passage and said fuse being engaged in said further passage.

6. A bobbin assembly according to claim 5 wherein the housing includes two recesses, one end of a power supply lead and one end of the wire of the coil being crimped together by a sleeve and engaged in one of said recess, and an end of the wire of the fuse and the end of another power supply lead being crimped together by a sleeve and engaged in the other of said recesses and the housing being provided with a further recess and the other end of the wire of the coil and the other end of the wire of the fuse being crimped together by a sleeve and engaged in said further recess.

7. A bobbin assembly according to claim 3 wherein the housing is formed with the grooves in two opposite parallel sidewalls which walls extend parallel to a line extending normal to the longitudinal axis of the core passage and wherein the housing is provided with a cover having two oppositely disposed inwardly directed flange portions which engage in said grooves of the housing so that the cover can be engaged with the housing by sliding the cover in a direction parallel to said line and away from said passage and there being cooperating abutment means provided on the housing and on the cover to prevent removal of the cover from the housing by continued movement in said direction and the arrangement being such that when a core is positioned in said core passage the cover cannot be removed from the housing.

8. A bobbin assembly according to claim 6 wherein the housing is formed with grooves in two opposite parallel sidewalls which walls extend parallel to a line extending normal to the longitudinal axis of the core passage and wherein the housing is provided with a cover having two oppositely disposed inwardly directed flange portions which engage in said grooves of the housing so that the cover can be engaged with the housing by sliding the cover in a direction parallel to said line and away from said passage and there being cooperating abutment means provided on the housing and on the cover to prevent removal of the cover from the housing by continued movement in said direction and the arrangement being such that when a core is positioned is said core passage the cover cannot be removed from the housing.

9. A bobbin assembly according to claim 7 wherein the housing is formed on a face of one of said flanges which extends generally normal to the longitudinal axis of the core passage and faces outwardly away from the other flange and wherein said recesses, in their longitudinal direction, extend in a plane parallel to said face.

v 10 A bobbin assembly according to claim 8 wherein the housing is formed on a face of one of said flanges which extends generally normal to the longitudinal axis of the core passage and faces outwardly away from the other flange and wherein said recesses, in their longitudinal direction, extend in a plane parallel to said face. 

1. A bobbin assembly comprising a bobbin having an axial core passage provided therein, an outwardly extending flange provided on each end of the bobbin and a coil of wire wound around the bobbin between the flanges, wherein the improvement comprises a housing provided on one of said flanges, and end of a power supply lead and an end of the wire of the coil being crimped together by a sleeve and engaged in said housing, a cover engaged with said housing and means to prevent removal of the cover from the housing When a core is engaged in said core passage.
 2. A bobbin assembly according to claim 1 wherein the housing includes a recess, said wire ends and said sleeve crimping said ends together being engaged in said recess.
 3. A bobbin assembly according to claim 1 wherein the housing includes two recesses, one of said recesses having said wire ends and said sleeve crimping said ends together engaged therein and the other recess having an end of another power supply lead and the other end of the wire of the coil together with a sleeve crimping said ends together engaged therein.
 4. A bobbin assembly according to claim 2 wherein a fuse is mounted on the bobbin and is connected in series with said coil.
 5. A bobbin assembly according to claim 4 wherein a further passage is formed in the bobbin and extends parallel to said core passage and said fuse being engaged in said further passage.
 6. A bobbin assembly according to claim 5 wherein the housing includes two recesses, one end of a power supply lead and one end of the wire of the coil being crimped together by a sleeve and engaged in one of said recess, and an end of the wire of the fuse and the end of another power supply lead being crimped together by a sleeve and engaged in the other of said recesses and the housing being provided with a further recess and the other end of the wire of the coil and the other end of the wire of the fuse being crimped together by a sleeve and engaged in said further recess.
 7. A bobbin assembly according to claim 3 wherein the housing is formed with the grooves in two opposite parallel sidewalls which walls extend parallel to a line extending normal to the longitudinal axis of the core passage and wherein the housing is provided with a cover having two oppositely disposed inwardly directed flange portions which engage in said grooves of the housing so that the cover can be engaged with the housing by sliding the cover in a direction parallel to said line and away from said passage and there being cooperating abutment means provided on the housing and on the cover to prevent removal of the cover from the housing by continued movement in said direction and the arrangement being such that when a core is positioned in said core passage the cover cannot be removed from the housing.
 8. A bobbin assembly according to claim 6 wherein the housing is formed with grooves in two opposite parallel sidewalls which walls extend parallel to a line extending normal to the longitudinal axis of the core passage and wherein the housing is provided with a cover having two oppositely disposed inwardly directed flange portions which engage in said grooves of the housing so that the cover can be engaged with the housing by sliding the cover in a direction parallel to said line and away from said passage and there being cooperating abutment means provided on the housing and on the cover to prevent removal of the cover from the housing by continued movement in said direction and the arrangement being such that when a core is positioned is said core passage the cover cannot be removed from the housing.
 9. A bobbin assembly according to claim 7 wherein the housing is formed on a face of one of said flanges which extends generally normal to the longitudinal axis of the core passage and faces outwardly away from the other flange and wherein said recesses, in their longitudinal direction, extend in a plane parallel to said face. 10 A bobbin assembly according to claim 8 wherein the housing is formed on a face of one of said flanges which extends generally normal to the longitudinal axis of the core passage and faces outwardly away from the other flange and wherein said recesses, in their longitudinal direction, extend in a plane parallel to said face. 